Fully automated popcorn production line including filling and packaging machines with a production capacity of 100 kg

The line consists of the following parts:

1 – Conveyor belt with collection tank.

2 – Vertical blast oven.

3 – Sifter.

4 – Seasoning unit.

5 – Flavor mixer.

6 – Pump.

screw conveyor

Automatic and safe transport of corn to the extruder feeder – robust design, food safety, and high operational efficiency. This screw conveyor is used to feed raw corn directly and continuously from the storage tank to the extruder feeder in a corn chips production line. The unit features a robust, all-food-grade 304 stainless steel construction, with integrated safety and impurity removal mechanisms to ensure safe and hygienic operation. It includes a 100kg capacity tank with a bottom opening for easy cleaning, a magnetic system for removing metal impurities, and a safety guard to prevent accidental contact with moving parts during operation.

⚙️ Operating Mechanism:

1️⃣ Corn feeding into the conveyor

✔️ The conveyor tank is filled with prepared corn kernels.

2️⃣ Screw conveyor transport to the extruder

✔️ The screw conveyor transports the corn smoothly and continuously to the extruder feeder.

3️⃣ Metal impurity filtration

✔️ Equipped with a magnetic filter to remove any metal impurities present in the corn.

4️⃣ Operator safety

✔️ Features a protective metal mesh guard to prevent accidental contact with moving parts during operation.

5️⃣ Easy cleaning

✔️ A dedicated bottom opening allows for easy emptying and cleaning of the unit after each batch. 📏 Technical Specifications:

✅ Machine Type: Spiral conveyor for corn feeding

✅ Hopper Capacity: 100 kg

✅ Material: Food-grade 304 stainless steel

✅ Metal Thickness: 2 mm

✅ Safety System: Safety mesh + magnetic system for removing impurities

✅ Voltage: 380/220 VAC – 50 Hz

✅ Power: 1.25 kW

✅ Dimensions:

✔️ Length: 300 cm

✔️ Width: 90 cm

✔️ Height: 250 cm

✅ Machine Number: 001

✅ Model: THV-2025 PV-Z

✅ Country of Origin: Turkey – High-quality industrial product, manufactured according to European standards. Robust design and high operational efficiency.

💡 Why is this spiral conveyor an essential component in the production line?

✔️ It ensures a consistent and safe flow of corn to the processing stage.

✔️ It provides complete operator safety during operation.

✔️ It is made of hygienic, rust-resistant materials that are easy to clean.

✔️ It helps improve production efficiency and reduces downtime.

Oven- Blasting head

Hot air popcorn popper without oil – a healthy technology, consistent performance, and high-quality construction. This main popcorn popper (oven) uses only hot air to pop the corn kernels, producing a healthy and light-textured popcorn without any added oil. Developed with American technology, this machine is designed for continuous operation (24/7) and is a key component of any popcorn production line. The oven operates on an open-loop system for continuous corn flow and features a vibratory feeder for precise control and accurate dosing of the corn kernels. Equipped with an Italian burner, it can operate on either gas or diesel fuel, depending on customer preference. The oven body is fully insulated with fiberglass to maintain heat and minimize energy loss.

⚙️ Operating Mechanism:

1️⃣ Automatic corn feeding

✔️ Corn is fed via an industrial vibratory feeder, the speed of which can be adjusted according to the desired quantity.

2️⃣ Hot air popcorn popping

✔️ Direct heating with hot air, without using any oil.

✔️ Rapid corn popping for perfectly crisp and fluffy popcorn.

3️⃣ Maintaining internal temperature

✔️ The oven is insulated with thermal fiberglass to maintain the internal temperature and reduce energy consumption.

4️⃣ Smart and user-friendly control

✔️ A stainless steel control panel with a touchscreen.

✔️ Supports two languages, as per customer request (e.g., Turkish + English / Arabic + English). 📏 Technical Specifications:

✅ Machine Type: Hot Air Popcorn Oven

✅ Operating System: Open circuit – Continuous feed

✅ Fuel Type: Gas or Diesel (as per customer request)

✅ Burner Type: Italian industrial burner

✅ Control System: Bilingual touchscreen + Stainless steel control panel

✅ Material: Food-grade 304 stainless steel

✅ Thermal Insulation: Heat-resistant fiberglass

✅ Voltage: 380/220VAC – 50Hz

✅ Power Consumption: 11.25 kW

✅ Dimensions:

✔️ Length: 250 cm

✔️ Width: 120 cm

✔️ Height: 220 cm

✅ Machine Number: 002

✅ Model: THV-2025BO-P

✅ Country of Origin: Turkey

💡 Why is this oven the ideal choice for popcorn production?

✔️ Because it operates without oil, producing a completely healthy product

✔️ Because it supports continuous operation 24/7

✔️ Because it features smart and user-friendly controls

✔️ Because it is fully thermally insulated for energy efficiency and consistent performance

The sieve

Separating unpopped kernels and chaff – precise sorting, automatic operation, and high-quality construction. The cylindrical screen is used immediately after the popcorn popping process to separate unpopped kernels (raw corn) and the remaining chaff (outer husk). It consists of a rotating perforated cylinder that allows the unpopped kernels to pass through the holes into a designated collection bin below the screen, while the popped popcorn continues along the production line. The screen rotates at a speed proportional to the popcorn popper's speed, and its speed is automatically controlled based on the production flow to ensure smooth and consistent performance.

⚙️ Operating Mechanism:

1️⃣ Receiving the popcorn and remaining kernels

✔️ The mixture exiting the popper (popped popcorn + unpopped kernels + chaff) enters the screen.

2️⃣ Automatic separation through the perforated cylinder

✔️ The unpopped kernels pass through the perforations and are collected in the lower bin.

✔️ The chaff (outer husk) is also separated independently.

3️⃣ Synchronized rotation with the popper speed

✔️ The screen rotates at a speed that matches the popper's output, with automatic control to adjust the speed as needed. 📏 Technical Specifications:

✅ Machine Type: Rotary sieve for separating unpopped kernels

✅ Rotation System: Automatic with speed control

✅ Separation Mechanism: Perforated screen to isolate unpopped kernels and chaff

✅ Material: Food-grade 304 stainless steel

✅ Voltage: 380/220VAC – 50Hz

✅ Power Consumption: 3.75 kW

✅ Dimensions:

✔️ Length: 200 cm

✔️ Width: 140 cm

✔️ Height: 190 cm

✅ Machine Number: 003

✅ Model: THV-2025BO-P

✅ Country of Origin: Turkey

💡 Why is this sieve an essential part of a popcorn production line?

✔️ It efficiently separates unpopped kernels.

✔️ It maintains the quality of the popped popcorn and prevents contamination with impurities.

✔️ It operates precisely and with a fully automated system.

✔️ It is made of safe, easy-to-clean materials.

Flavor coating cylinder

Even and precise flavor distribution on popcorn – Smart design, balanced performance, and optimal flavoring results. The flavorer is an essential piece of equipment in the final flavoring stage of the popcorn production line. It evenly mixes the flavor with the popcorn kernels using a rotating drum that operates at a variable speed, electronically controlled by an industrial inverter. The flavorer is equipped with a state-of-the-art American-made flavor spray nozzle, precisely calibrated to deliver the perfect amount of flavor. It also features a dust cover at the product discharge point and robust industrial casters for easy movement and cleaning within the production facility.

⚙️ Operating Mechanism:

1️⃣ Balanced rotation of kernels inside the drum

✔️ The popcorn is rotated slowly and evenly inside the drum to ensure optimal flavor coating.

2️⃣ Electronic flavor spraying

✔️ A professional flavor spray nozzle distributes the powder precisely and uniformly over all the kernels.

✔️ Calibrated to suit the type of flavor and the desired level of coating.

3️⃣ Prevention of clumping and impurities

✔️ The internal baffles are designed to prevent flavor buildup and clumping inside the drum.

✔️ Equipped with a mechanism to remove small kernels or unwanted impurities.

4️⃣ Control of flavoring time

✔️ The time the product spends inside the flavorer can be adjusted to achieve the desired level of flavor.

📏 Technical Specifications:

✅ Machine Type: Rotating and flavoring drum for popcorn

✅ Control System: Electronic inverter for speed control + adjustable flavor spray nozzle

✅ Flavor Spray Nozzle: Adjustable, American-made model

✅ Impurity Removal Mechanism: Integrated within the drum

✅ Material: Food-grade 304 stainless steel

✅ Voltage: 380/220VAC – 50Hz

✅ Power Consumption: 3.75 kW

✅ Dimensions:

✔️ Length: 300 cm

✔️ Width: 90 cm

✔️ Height: 150 cm

✅ Machine Number: 004

✅ Model: THV-2025 BO-P

✅ Country of Origin: Turkey – High-quality industrial product, manufactured according to European standards. Robust design and high operational efficiency.

💡 What makes this popcorn flavoring machine stand out?

✔️ Perfect and even coating of each popcorn kernel

✔️ Clump-free popcorn thanks to the smart drum design

✔️ Equipped with a professional, adjustable flavor spray nozzle

✔️ Easy to clean and easy to move around the shop

Two flavor mixer tanks

Perfect blending of flavor and oil using indirect heating technology – double jacket design, high-quality construction, and precise temperature control. This mixer is used to prepare the flavor and oil mixture for coating snacks or popcorn. The ingredients are mixed in a 200-liter tank with a double-jacket design, which allows for indirect heating using hot water, ensuring that the oil does not burn or the flavor is not compromised. The mixer and its integrated feed pump are mounted on a single, robust frame made of galvanized steel and fully covered with food-grade 304 stainless steel. Heavy-duty casters are included for easy movement and cleaning in the production area.

⚙️ Operating Principle:

1️⃣ Preparing the flavor and oil mixture in the mixer

✔️ The double-jacket wall is heated with hot water to warm the mixture without burning or direct contact with the heat source.

2️⃣ Direct connection to the pump

✔️ The mixer and pump are mounted on a single base to ensure integrated and seamless operation.

3️⃣ Precise temperature and level monitoring

✔️ Equipped with a digital temperature gauge to monitor the water temperature inside the jacket.

✔️ Includes a level indicator to measure the amount of hot water in the tank.

📏 Technical Specifications:

✅ Machine Type: Flavor and Oil Mixer with Double Jacket System

✅ Capacity: 200 liters

✅ Heating System: Indirect heating using hot water

✅ Control Mechanism: Temperature controller + water level indicator

✅ Material: Food-grade 304 stainless steel

✅ Voltage: 380/220VAC – 50Hz

✅ Power Consumption: 3.75 kW

✅ Dimensions:

✔️ Length: 150 cm

✔️ Width: 120 cm

✔️ Height: 170 cm

✅ Machine Number: 005

✅ Model: THV-2025BO-P

✅ Country of Origin: Turkey – High-quality industrial product manufactured according to European standards. Robust design and high operational efficiency.

💡 Why is this mixer an essential part of snack and popcorn production lines?

✔️ It ensures a homogeneous and safe mixing of flavor and oil.

✔️ It prevents oil from burning and maintains flavor quality.

✔️ It is integrated with a pump on a practical, easy-to-move chassis.

✔️ It is equipped with monitoring and control instruments for easy operation and complete control.

Flavor pump

Precise and economical flavor dispensing – American technology, electronic control, and a robust industrial design. The flavor pump dispenses the oil and flavor mixture to the seasoning nozzles evenly and precisely. It utilizes an innovative alternating suction and discharge system, an efficient American technology that ensures consistent flavor and minimizes waste. The pump housing is made of high-quality, durable European aluminum and mounted on a sturdy 304 food-grade stainless steel base. Industrial casters facilitate easy movement within the production line. The pump is powered by a reliable geared motor and features a food-grade silicone hose for safe food contact and easy cleaning.

⚙️ Operating Mechanism:

1️⃣ Alternating Suction and Discharge of Flavor Mixture

✔️ The flavor mixture is drawn from the mixer and precisely pumped to the seasoning nozzles.

✔️ The alternating system ensures continuous and consistent dispensing without interruption.

2️⃣ Precise Electronic Flow Control

✔️ Equipped with an inverter to electronically adjust the flavor dosage according to the production line speed and product type.

3️⃣ Easy Maintenance and Hygiene

✔️ The food-grade silicone hose is easy to remove, clean, and sanitize.

📏 Technical Specifications:

✅ Device Type: Flavoring pump with alternating suction and pumping system

✅ Frame Material: Solid aluminum

✅ Base Stand: Food-grade 304 stainless steel with casters

✅ Drive System: Industrial geared motor

✅ Control System: Electronic inverter for precise flow control

✅ Hose: High-quality food-grade silicone

✅ Voltage: 380/220VAC – 50Hz

✅ Power Consumption: 1.125 kW

✅ Dimensions:

✔️ Length: 80 cm

✔️ Width: 60 cm

✔️ Height: 70 cm

✅ Machine Number: 006

✅ Model: THV-2025BO-P

✅ Country of Origin: Turkey

💡 What makes this pump stand out in the production line?

✔️ Precise flavor dosing with full electronic control

✔️ Designed to minimize waste and maximize flavor consistency

✔️ Easy to move and maintain

✔️ Food-safe and made with high-quality materials

2 Packing Machine Feeder Conveyor Line

Precise and balanced product transfer to maintain quality. The conveyor belt is a crucial part of the chip production process, ensuring efficient transfer of the product from the flavoring stage to two packaging machines, while maintaining the integrity of the chips by preventing breakage through a precise and fully automated distribution system. Advanced operating mechanism:

1️⃣ Precise electronic control system: The product transfer speed is controlled by an electronic control circuit equipped with modern sensors, allowing for balanced product feeding according to the capacity of the packaging machines.

✅ Equipped with a hopper and vibrator to ensure a smooth flow of chips without any accumulation or jamming.

✅ Fully automatic operation minimizes manual intervention and maximizes production efficiency.

2️⃣ Advanced conveyor belt design: Features a Z-shaped PVC belt for easy product transfer at an optimal angle, ensuring smooth flow without affecting the shape of the chips.

✅ Made of food-grade 304 stainless steel for the highest hygiene and quality standards.

✅ Its design minimizes vibrations and shocks, protecting the product from breakage.

3️⃣ Smart sensors for enhanced performance: Equipped with advanced electronic sensors that automatically adjust the speed and flow of the product, preventing any accumulation or congestion on the production line.

✅ Ensures even distribution of the product between the packaging machines for consistent and reliable production.

4️⃣ Durable and easy-to-clean design: Made entirely of food-grade 304 stainless steel for rust resistance and easy cleaning, with a robust structure to withstand continuous use in industrial environments.

✅ Equipped with sturdy casters for easy movement and maintenance. Technical Specifications:

✅ Material: Made entirely of food-grade 304 stainless steel for the highest hygiene and quality standards.

✅ Power: 5.25 kW | 380/220 V | 50 Hz

✅ Dimensions:

Length: 8 cm

Width: 90 cm

Height: 380 cm

✅ Machine Number: 007

✅ Model: THV-2025 BO-P

✅ Country of Origin: Turkey – High-quality industrial product, manufactured according to European standards. Robust design and high operational efficiency.

Features of the Conveyor Belt:

✔️ Precise electronic control system with sensors for automatic adjustment of product transport speed.

✔️ Z-shaped PVC belt ensures smooth and consistent product flow without affecting product quality.

✔️ Impact and vibration-resistant design to prevent product damage.

✔️ Hopper and vibrator ensure even product flow and prevent product buildup during transport.

✔️ Made entirely of food-grade 304 stainless steel for rust resistance and easy cleaning.

✔️ Equipped with sturdy casters for easy movement and cleaning, making it ideal for industrial environments.

💡 The perfect solution for efficient product transport and ensuring the highest quality in production!

Continuous system weight packaging machines No.2

Precision and speed in packaging food products with advanced systems. This weighing and packaging machine is designed using the latest global technologies to ensure high speed, continuous operation 24/7, and superior accuracy in weighing and packaging. It features advanced control systems, a precise optical sensor, and an integrated electronic control system that guarantees high efficiency and consistent production. Advanced operating mechanism:

1️⃣ Precise and flexible packaging system: Automatic packaging of potato crisps, chips, seeds, and nuts. It utilizes a smart weighing system to ensure accurate packaging and minimize waste.

2️⃣ Advanced electronic control for smooth operation: A sophisticated PLC system from DELTA for fast response and precise control. A 7-inch DELTA touchscreen for easy operation. A precise temperature control system from OMRON allows temperature adjustment via the screen to ensure seal quality.

3️⃣ High performance with powerful motors: Equipped with motors and gearboxes for controlling the conveyor belt and sealing jaws, ensuring stable operation. A linear motor for automatic film roll positioning, controlled via the screen. A linear motor for film tension compensation with an end-of-roll alert system.

4️⃣ Safe and durable design: Safety sensors protect the operator from operational errors. A daily and total production counter for performance monitoring and efficient production tracking. The frame is made entirely of food-grade 304 stainless steel for hygiene and product safety. All parts that come into contact with the product are made of 304 stainless steel, meeting food-grade quality standards.

5️⃣ Flexible roll handling: The roll width can be customized to suit the customer's needs, allowing for the packaging of various products. Maximum roll length: 320 mm. An Italian-made roll forming unit, easily interchangeable for increased operational efficiency. Supports the use of a pre-formed film roll for a tight and high-quality seal.

6️⃣ Additional features for enhanced efficiency: A conveyor belt (Z-type PVC) with a 304 stainless steel frame and automatic feeding system. A conveyor belt for finished packages to facilitate transport and storage. A date printer to print product information directly on the package. A HIGH DREAM smart weighing system for high accuracy. A 304 stainless steel platform for the weighing device, ensuring stability and reliability. Technical Specifications:

✅ Material: Made entirely of food-grade 304 stainless steel for hygiene and quality.

✅ Power: 5.75 kW | 380/220 V | 50 Hz.

✅ Dimensions:

Length: 200 cm

Width: 130 cm

Height: 420 cm

🔢 Machine Number: 008

✅ Model: THV-2025 BO-P

✅ Country of Origin: Turkey. Durable design for high performance:

✔️ High weighing accuracy with a smart weighing system.

✔️ Comprehensive electronic control for optimal operation.

✔️ Comprehensive safety features with safety sensors to protect the operator.

✔️ Flexible packaging roll handling to suit customer needs.

✔️ High-quality European components for machine durability. Features of the weighing packaging machine:

✔️ High speed and accuracy in packaging.

✔️ A sophisticated PLC control system ensures smooth and responsive operation.

✔️ Durable 304 stainless steel construction guarantees hygiene and product safety.

✔️ User-friendly design and easy maintenance for extended machine lifespan.

✔️ Integrated safety systems to protect operators during operation.

💡 The ideal solution for efficient and precise packaging of food products!

Electrical parts and control panels

Circuit breakers: Schneider brand

Contactors: Schneider brand

Control panel: Delta

Inverters: Delta

Motors: GAMAK

Gearboxes: YILMAZ

Or as per customer request

basic information

🎯 Healthy Popcorn Production Line – Hot Air Technology Innovate and attract your customers with a healthy and modern product that meets the needs of today's consumers! From Al Huda International, we present to you our hot air popcorn production line – a complete industrial system that pops corn kernels without using any oil, resulting in a 100% healthy product, perfect for those who love clean eating and a healthy lifestyle.

🔍 Why choose Al Huda's popcorn production line?

✅ Hot air technology: The line pops the corn kernels using precisely controlled hot air, eliminating the need for any oils or fats. The result? Crispy, light, and completely healthy popcorn, ideal for children, athletes, and those looking for a lighter alternative to traditional snacks.

✅ A complete, turnkey solution: The line includes all production stages, from the automatic feeding unit, to the popping chamber, cooling systems, optional healthy flavor blending, and packaging. All designed according to the latest international food industry standards.

✅ High operational efficiency: The line boasts a high production capacity of up to hundreds of kilograms per day, with flexible control over temperature, popping speed, and air pressure, adaptable to different corn varieties.

✅ Made in Turkey with German quality: All components of the line are manufactured in Turkey at Al Huda's own factories, using proven German technology that has been reliable for over 20 years. Every machine undergoes rigorous quality and performance testing before delivery. ✅ 100% Hygienic Manufacturing Materials: All parts that come into contact with the product are made of high-quality 304 food-grade stainless steel, ensuring product safety and ease of cleaning and maintenance.

✅ Genuine Warranty and Support: We offer comprehensive warranty coverage for the entire production line, along with on-site installation and commissioning services, comprehensive technical training for your staff, and ongoing after-sales support.

📐 Required Space for the Production Line

▪️ Total Line Length: 18 meters

▪️ Width: 3 meters

▪️ Required Operating Area: 150 square meters

🏭 Al Huda International Company – Manufacturing with Confidence: At Al Huda, we offer you the culmination of over 20 years of experience in manufacturing snack and cracker production lines. We provide industrial lines that meet European standards and offer reliable performance, certified with international ISO and CE quality standards, and backed by comprehensive technical support from contract signing to full operational production.

✳️ With Al Huda, you're not just buying a machine; you're investing in a successful business, supported by technology, quality, and commitment.

📩 For inquiries regarding pricing, production capacity, or to design your factory layout based on your available space – please don't hesitate to contact us. We are always at your service.